Flip Top Rolling Tool Cart

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Project by Woodster73 posted 09-25-2016 04:15 AM 1810 views 3 times favorited 3 comments Add to Favorites Watch

This is a rolling cart with a flip top I built to try to maximize some shop space (I’m just in process of putting a 1-stall garage shop together). I looked at several designs and decided on a slightly beefed up version of one I saw online, I’ll try to find the link to where I saw the design. The carcase is built from 7-ply plywood, the flip top is plywood with cedar spacers. I used cedar mostly because I had some extra laying around, and because I love the way it smells while working it!

I started by cutting most of the plywood for the carcase and top. I don’t have a jointer, so I used my “Big Bertha” jointer plane to plane the Cedar flat on one face and one edge, then used the planer and tablesaw to square the other face and edge. I relieved all the edges with a block plane, then glued up the base and sides, and drilled the holes for the casters. Next, I drilled the holes for the metal pipe I used for the axle in the top.

I then realized I hadn’t cut the slots in the sides that receive the bolts from the top, which turned a really easy pre assembly cut into a pain. I ended up building a little jig and using the router to cut the slots in the sides, as they really need to be in alignment with the center of rotation for the top.

The top is constructed with plywood separated by a cedar frame with the metal rod sandwiched very tightly between them. You can see in the photos how it is constructed, and I used glue and screw construction throughout for stability. I then assembled the top into the carcase using fender washers, which required a fair amount of slight adjusting to fit. I drilled holes through the rod to accommodate large pins. The edge bolts have a bolt recessed into the top with an eye bolt attached to the top bolt. I assembled the whole thing, then flipped it over about a hundred times :).

I mounted the planer and the other two tools with lag bolts that go all the way through to the opposite side plywood for strength. I mounted the planer across the top so I didn’t have to remove the adjustment handle when I flipped it over. I rolled it around the shop for a few days, and the next weekend built the drawer for the bottom. I put a light coat of spray lacquer to protect it a bit.

I made my fair share of mistakes and definitely learned some lessons in the construction, but overall I like the cart. So far it’s rock solid, even with the quite heavy planer mounted. It rolls easily and flips with one hand. Thanks for checking it out!

3 comments so far

View  woodshaver Tony C   's profile

woodshaver Tony C

6202 posts in 3526 days

#1 posted 09-25-2016 03:42 PM

A great way to save space in a small shop. I like the storage drawer on the bottom. I put my storage on the side to keep the height low. We do what works! Nice job!

-- St Augustine FL, Experience is the sum of our mistakes!

View Woodster73's profile


19 posts in 1248 days

#2 posted 11-09-2016 03:48 AM

Thanks, Tony! I had a lot of fun building it, and it’s still rock solid thus far!

You ever been to O’Steen’s? Love me some fried shrimp…

View  woodshaver Tony C   's profile

woodshaver Tony C

6202 posts in 3526 days

#3 posted 11-09-2016 01:02 PM

I know you are enjoying that flip cart. It’s such a space saver. I just wish I made my cart years ago; it just makes so much sense in a small shop.

O’steen’s YES! we have been there many times. Sad to say they had storm flooding during hurricane Mathew in October. I believe they have rectified all the damage by now. Next time we head down to O’steens I’ll be thinking of you while enjoying some of their delicious fried shrimp! That sounded mean but not meant to be! :P

-- St Augustine FL, Experience is the sum of our mistakes!

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